Ventilated helmet system

ABSTRACT

A ventilation system for a helmet that incorporates various elements in different embodiments, including air flow channels in the safety padding, a shell on the safety padding underneath the external shell, thickening of the external shell in the areas of the air flow channels, extrusions in the external shell to facilitate air flow in the air flow channels, and vents in the external shell to feed and exhaust air flow.

BACKGROUND OF THE INVENTION

1. Field of Invention

The invention relates in general to the field of helmets, and more specifically to a ventilation system for a motorcycle helmet.

2. Description of Related Art

Safety helmets for motorcycles are typically made in the form of a complete cap that provides an opening in the area of the user's eyes. The helmets are generally provided with an external shell, made from a rigid and strong material, such as polycarbonate, or composite materials, coupled with safety padding inside the shell. The safety padding is often made of expanded polystyrene, expanded polypropylene, or foamed polyurethane, and is itself often lined with a soft material in order to provide comfort to the wearer.

Ventilation is often required both for cooling and to exhaust moisture caused by sweat coming from the rider. The need for ventilation occurs both in the volume under the main shell and in the area of the cheek bar.

Prior art devices have addressed the need for ventilation in motorcycle helmets. For example, U.S. Pat. No. 5,086,520 to Arai utilizes an air inlet on the top portion of the shell to allow for the introduction of air into the shell. This device delivers air to the top of the head and is limited in the manner in which it can cool or dehumidify the interior of the helmet shell.

U.S. Pat. No. 4,555,816 to Broersma illustrates a motorcycle helmet which utilizes air inlets in the cheek bar. Although the air inlet is in the external portion of the cheek bar, the air itself is routed outside the foamed polyurethane liner and then through passages where it can then ventilate the sides, top, and rear of the user's head.

A safety concern for helmets is the helmet's ability to resist penetration of an object through the outer shell. In some helmets, the safety padding is made of expanded polystyrene. In such helmets, the safety padding may tend to split if penetrated by an object, especially if the safety padding has been thinned or had channels added. This aspect of the safety padding may require a helmet to have other modifications in conjunction with adding channels to the safety padding in order to provide maximal penetration resistance.

Prior methods are limited in their ability to provide ventilation to cool the rider's head. What is called for is a better ventilation system for a helmet that maintains the integrity and safety of the helmet. Such a helmet may utilize better ventilation channels while maintaining maximum penetration protection.

BRIEF SUMMARY OF THE INVENTION

A ventilation system for a helmet that incorporates various elements in different embodiments, including air flow channels in the safety padding, a shell on the safety padding underneath the external shell, thickening of the external shell in the areas of the air flow channels, extrusions in the external shell to facilitate air flow in the air flow channels, and vents in the external shell to feed and exhaust air flow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a helmet according to one embodiment of the present invention.

FIG. 2 is a side view of a helmet according to one embodiment of the present invention.

FIG. 3 is a side cut-away view of a helmet according to one embodiment of the present invention.

FIG. 4 is a front cut-away view of a helmet according to one embodiment of the present invention.

FIG. 5 is a rear view of the safety padding of the helmet according to one embodiment of the present invention.

FIG. 6 is a bottom view of the safety padding of the helmet according to one embodiment of the present invention.

FIG. 7 is a side cut-away view of a helmet according to one embodiment of the present invention.

FIG. 8 is a front cut-away view of a helmet according to one embodiment of the present invention.

FIG. 9 is a side cut-away view of a helmet according to one embodiment of the present invention.

FIG. 10 is a front cut-away view of a helmet according to one embodiment of the present invention.

DETAILED DESCRIPTION

In some embodiments of the present invention, as seen in FIG. 1, a motorcycle helmet 100 has an outer shell 101 and safety padding 102. The outer shell has a chin bar 107 in some embodiments. In some embodiments, the chin bar 107 is integral to the outer shell 101. In some embodiments, the chin bar 107 is attached to the outer shell 101. The face opening 106 in the outer shell 101 is an opening that allows for the user to see out and is typically large enough to allow for the user to wear a pair of goggles or other eyewear. The visor 103 is attached to the outer shell 101 and can be used to provide shade to the face opening 106 while the helmet 100 is worn by the user.

Above the face opening 106 in the outer shell 101 are front vents 110, 111. In some embodiments, the front vents 110, 111 are capped by front vent mechanisms 104, 105 which can be opened and closed to adjust the amount of airflow that can travel through the front vents 110, 111. In some embodiments, the front vents 110, 111 are located under the visor 103 and above the face opening 106. In some embodiments, the front vents 110, 111 are located in the outer shell 101 in an area substantially over channels in the safety padding. The front vents 110, 111 allow for fluidic coupling of the channels in the safety padding, or of the channels in the outer shell, or of both, to the outside airflow.

In some embodiments of the present invention, as seen in FIG. 2, the outer shell has rear vents. In some embodiments, the outer shell has one or more upper rear vent 121 and one or more lower rear vent 123. The upper rear vents 121 may have an upper rear vent cover 120 in some embodiments. The lower rear vents 123 may have a lower rear vent cover 122 in some embodiments. In some embodiments, the rear vents are located in an area substantially over channels in the safety padding. The rear vents may allow for fluidic coupling of the channels in the safety padding to the outside airflow.

FIGS. 3 and 4 represent typical cross-sections of the motorcycle helmet 100 according to one embodiment of the present invention. The outer shell 101 receives airflow 302, 303 through a front vent 110. Air flow may exhaust through upper rear vent 121 and the lower rear vent 123. The front vent 110, the upper rear vent 121, and the lower rear vent 123 may located such that they substantially overlay the airflow channels in the safety padding in some embodiments. In some embodiments, there are two front vents, two upper rear vents, and two lower rear vents.

In some embodiments of the present invention, the air flows through outer channels 401 along the exterior surface of the safety padding 102 in some embodiments. The airflow 303, 304, 305, 306 through the safety padding 102 flows through holes 402 that fluidically couple the outer channels 401 along the exterior of the safety padding 102 to the inner surface of the safety padding 102. The safety padding 102 has inner channels 406 along its inner surface in some embodiments. The bottom surface 307 of the outer channels 401 are coupled to the bottom surface 308 of the inner channels 406 via holes 402 in some embodiments. The comfort liner 301 resides along the inside of the safety padding 102 in some embodiments.

In some embodiments, the holes are significantly larger. The increased size of the holes and channels enhances ventilation of the helmet interior even when the relative airflow speed outside the helmet is minimal.

In some embodiments of the present invention, the outer shell 101 has raised areas 404, 405 that contribute to the formation of an airflow channel. The raised areas 404, 405 may substantially overlay the outer channels 401 in the safety padding 102. In some embodiments, the space 403 between the safety padding 102 and the outer shell 101 may allow for some air flow, even in the area away from the outer channels 401. In some embodiments, the outer contour of the safety padding in the areas other than the outer channels 401 substantially conforms to the inner contour of the outer shell 101. In some embodiments, the raised areas 404, 405 of the outer shell 101 may be reinforced. In some embodiments, the regions may not be raised but are reinforced. In some embodiments, the reinforcement consists of additional thickness in the outer shell.

The reinforcement of the outer shell enhances the penetration resistance in the area of reinforcement. In areas where the safety padding may be thinner or partially removed to allow for better airflow or for other reasons, the reinforcement of the outer shell can be used to compensate for any possible reduction of strength, or reduction of penetration resistance, of the helmet in this area.

In some embodiments of the present invention, as seen in FIGS. 5 and 6, the safety padding 102 may have a padding shell 501. In some embodiments, the padding shell 501 resides on the outer surface of the safety padding 102. In some embodiments, the padding shell 501 covers a portion of the outer surface of the safety padding 102, whereas the remainder 502 of the outer surface of the safety padding not covered by the padding shell 501. In some embodiments, the padding shell 501 covers substantially all of the outer surface of the safety padding 102. In some embodiments, the padding shell 501 substantially conforms to the contours of the outer surface of the safety padding 102. In some embodiments, the padding shell 501 is a polycarbonate material. In some embodiments, the polycarbonate material is approximately 0.050 inches thick.

In one embodiment of the present invention, as seen in FIG. 5, the padding shell 501 resides on the outer surface of the safety padding. The padding shell 501 conforms to the contours of the outer surface of the safety padding 102. The padding shell 501 does not cover all of the outer surface of the safety padding 102 in some embodiments. The outer channels 504, 505 have their surface covered by the padding shell 501. The outer channels run substantially longitudinally in some embodiments. Portions of the interior surfaces of the holes 506, 507 in the outer channels 504, 505 are covered by the padding shell 501 in some embodiments. All of the interior surfaces of the holes 506, 507 in the outer channels 504, 505 are covered by the padding shell 501 in some embodiments.

In some embodiments of the present invention, there is one outer channel on the outer surface of the safety padding. In some embodiments, there are two outer channels on the outer surface of the safety padding. In some embodiments, there is a plurality of outer channels on the outer surface of the safety padding.

The padding shell 501 is bonded to the outer surface of the safety padding 102 in some embodiments. The padding shell 501 may increase the penetration resistance of the helmet in a variety of ways. The padding shell itself typically is much more resistant to penetration than the safety padding that it covers. Should an item penetrate the outer shell, it must then also penetrate the padding shell in some areas. Should an item penetrate the outer shell, the item may then split the safety padding and force the split pieces apart. Should the item penetrate a helmet that has a padding shell, it will be harder for the pieces of the safety padding to be split apart because of the bonding of the padding shell to the safety liner. In some embodiments, the material of the padding shell is not as susceptible to splitting, and may anchor the safety padding together.

In some embodiments, the padding shell and safety padding form a composite to create a stronger structure. In some embodiments, the padding shell is molded into the safety padding. In some embodiments, the padding shell is bonded to the safety padding. In some embodiments, the padding shell is attached to the safety padding using other methods.

In some embodiments, as seen in FIG. 6, the safety padding 102 has inner channels 604, 605 on the interior surface. In some embodiments, the safety padding 102 has one inner channel on its interior surface. In some embodiments, the safety padding 102 has a plurality of inner channels on its interior surface. In some embodiments, the outer channels 504, 505 substantially overlay the inner channels 604, 605. In some embodiments, the through holes 506, 507 in the safety padding 102 directly couple the outer channels 504, 505 and the inner channels 604, 605. In some embodiments, the through holes are approximately 20 mm wide and 70 mm long. In some embodiments, the outer channels are approximately 5 mm to 10 mm deep.

FIGS. 7 and 8 represent typical cross-sections of the motorcycle helmet 550 according to another embodiment of the present invention. The outer shell 551 receives airflow 552 through one or more front vents 553. Air flow may exhaust through one or more upper rear vents 554. In some embodiments, there is one or more lower rear vents. The front vents 553, the upper rear vents 554, and the lower rear vents may be located such that they substantially overlay the airflow channels in the safety padding 561 in some embodiments. In some embodiments, there are two front vents, two upper rear vents, and two lower rear vents.

A face opening vent 555 allows for airflow 556 for additional ventilation entering from the face opening 106 in some embodiments. In some embodiments, there are two face opening vents 555. In some embodiments, there are a plurality of face opening vents 555. In some embodiments, the face opening vent 555 is a continuous vent. A face opening shield 557 may be used to direct airflow 556 into the helmet 550. In some embodiments, the face opening shield 555 directs airflow into the inner channels. The comfort liner 558 lines the inner surface of the safety padding 561 in some embodiments. Gaps 560 in the comfort liner 558 facilitate ventilation into the interior of the helmet 550.

In some embodiments, the safety padding 561 has larger channels for greater ventilation. In some embodiments, the safety padding has internal reinforcements 559. In some embodiments, the internal reinforcements 559 are made of ABS. In some embodiments, the internal reinforcements are molded into the safety padding 561. The internal reinforcements 559 add strength to the safety padding 561, especially in the areas of the larger channels. In some embodiments, the safety padding 561 has larger channels, internal reinforcements 559, and a padding shell.

In some embodiments, the outer shell 551 of the helmet 550 has raised areas 562 that contribute to the formation of an airflow channel. The raised areas 562 may substantially overlay the larger channels 563 in the safety padding 561. In some embodiments, the front vents 553 are located at the front of the raised areas 562. In some embodiments, the outer contour of the safety padding in the areas other than the larger channels 563 substantially conforms to the inner contour of the outer shell 551. In some embodiments, the raised areas 562 of the outer shell 551 may be reinforced. In some embodiments, the regions may not be raised but are reinforced. In some embodiments, the reinforcement consists of additional thickness in the outer shell.

FIGS. 9 and 10 represent typical cross-sections of the motorcycle helmet 650 according to another embodiment of the present invention. The outer shell 651 receives airflow 652 through one or more front vents 653. Air flow may exhaust through one or more upper rear vents 654. In some embodiments, there is one or more lower rear vents 670. The front vents 653, the upper rear vents 654, and the lower rear vents 670 may be located such that they substantially overlay the airflow channels in the safety padding 661 in some embodiments. In some embodiments, there are two front vents 653, two upper rear vents 654, and two lower rear vents 670.

A face opening vent 655 allows for airflow 656 for additional ventilation entering from the face opening 106 in some embodiments. In some embodiments, there are two face opening vents 655. In some embodiments, there are a plurality of face opening vents 655. A face opening shield 657 may be used to direct airflow 656 into the helmet 650. In some embodiments, the face opening shield 655 directs airflow into the inner channels 671. The comfort liner 658 lines the inner surface of the safety padding 661 in some embodiments. Gaps 660 in the comfort liner 658 facilitate ventilation into the interior of the helmet 650.

In some embodiments, the safety padding has internal reinforcements 659. In some embodiments, the internal reinforcements are made of ABS. In some embodiments, the outer shell 651 of the helmet 650 has raised areas 662 that contribute to the formation of an airflow channel. The raised areas 662 may substantially overlay the outer channels 663 in the safety padding 661. In some embodiments, the raised areas 662 may be reinforced.

As evident from the above description, a wide variety of embodiments may be configured from the description given herein and additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader aspects is, therefore, not limited to the specific details, representative apparatus and illustrative examples shown and described. Accordingly, departures from such details may be made without departing from the spirit or scope of the applicant's general inventive concept. 

1. A helmet comprising: an external shell; safety padding, said safety padding substantially residing within said external shell; and a padding shell, wherein said padding shell substantially conforms to the outer surface of said safety padding.
 2. The helmet of claim 1, wherein said safety padding comprises a plurality of outer channels.
 3. The helmet of claim 2, wherein said plurality of outer channels are formed in said safety padding along its exterior.
 4. The helmet of claim 3, wherein said plurality of outer channels are formed substantially longitudinally.
 5. The helmet of claim 3, wherein some portions of said plurality of outer channels comprise holes through to the inner surface of said safety padding.
 6. The helmet of claim 1 wherein said outer shell comprises reinforced areas.
 7. The helmet of claim 2 wherein said outer shell comprises reinforced areas.
 8. The helmet of claim 7 wherein said reinforced areas substantially overlay said plurality of outer channels.
 9. The helmet of claim 3 wherein said outer shell comprises reinforced areas.
 10. The helmet of claim 9 wherein said reinforced areas substantially overlay said plurality of outer channels.
 11. The helmet of claim 2 wherein said outer shell comprises front vents, said front vents located substantially over the forward area of one or more of said plurality of outer channels.
 12. The helmet of claim 3 wherein said outer shell comprises front vents, said front vents located substantially over the forward area of one or more of said plurality of outer channels.
 13. The helmet of claim 11 wherein said outer shell further comprises rear vents, said rear vents located substantially over the aft area of one or more of said plurality of outer channels.
 14. The helmet of claim 12 wherein said outer shell further comprises rear vents, said rear vents located substantially over the aft area of one or more of said plurality of channels.
 15. A helmet comprising: an external shell; safety padding, said safety padding substantially residing within said external shell, wherein said safety padding comprises a plurality of outer channels and a plurality of inner channels; and a padding shell, wherein said padding shell substantially conforms to the outer surface of said safety padding.
 16. The helmet of claim 15 wherein said plurality of outer channels and said plurality of inner channels are formed substantially longitudinally.
 17. The helmet of claim 15, wherein said safety padding further comprises holes from said plurality of outer channels through to said plurality of inner channels.
 18. The helmet of claim 17 wherein said outer shell comprises reinforced areas.
 19. The helmet of claim 18 wherein said reinforced areas substantially overlay said plurality of outer channels.
 20. The helmet of claim 19 wherein said outer shell comprises front vents, said front vents located substantially over the forward area of one or more of said plurality of outer channels.
 21. The helmet of claim 20 wherein said outer shell further comprises rear vents, said rear vents located substantially over the aft area of one or more of said plurality of outer channels.
 22. A helmet comprising: an external shell; safety padding within said external shell, wherein said safety padding comprises a plurality of channels.
 23. The helmet of claim 22, wherein said plurality of channels are formed in said safety padding along its exterior.
 24. The helmet of claim 23, wherein said plurality of channels are formed substantially longitudinally.
 25. The helmet of claim 23, wherein some portions of said plurality of channels comprise holes through to the inner surface of said safety padding.
 26. The helmet of claim 22 wherein said outer shell comprises reinforced areas.
 27. The helmet of claim 23 wherein said outer shell comprises reinforced areas.
 28. The helmet of claim 26 wherein said reinforced areas substantially overlay said plurality of channels.
 29. The helmet of claim 27 wherein said reinforced areas substantially overlay said plurality of channels.
 30. The helmet of claim 22 wherein said outer shell comprises front vents, said front vents located substantially over the forward area of one or more of said plurality of channels.
 31. The helmet of claim 23 wherein said outer shell comprises front vents, said front vents located substantially over the forward area of one or more of said plurality of channels.
 32. The helmet of claim 30 wherein said outer shell further comprises rear vents, said rear vents located substantially over the aft area of one or more of said plurality of channels.
 33. The helmet of claim 31 wherein said outer shell further comprises rear vents, said rear vents located substantially over the aft area of one or more of said plurality of channels.
 34. The helmet of claim 28 wherein said outer shell comprises front vents, said front vents located substantially over the forward area of one or more of said plurality of channels.
 35. The helmet of claim 29 wherein said outer shell comprises front vents, said front vents located substantially over the forward area of one or more of said plurality of channels.
 36. The helmet of claim 34 wherein said outer shell further comprises rear vents, said rear vents located substantially over the aft area of one or more of said plurality of channels.
 37. The helmet of claim 35 wherein said outer shell further comprises rear vents, said rear vents located substantially over the aft area of one or more of said plurality of channels.
 38. A helmet comprising: an external shell, said external shell comprising: one or more raised areas, said raised areas forming internal airflow channels; and one or more front vents, wherein said front vents are located along said extrusions at their forward end.
 39. The helmet of claim 38 further comprising safety padding.
 40. The helmet of claim 39 wherein said safety padding comprises a one or more air flow channels.
 41. The helmet of claim 40 wherein said raised areas substantially overlay said air flow channels.
 42. A helmet comprising: an external shell; and safety padding within said external shell, said safety padding comprising internal reinforcements.
 43. The helmet of claim 42 wherein said safety padding further comprises through holes from the outer surface of said safety padding to the inner surface of said safety padding.
 44. The helmet of claim 43 wherein said internal reinforcements are adapted to reinforce said safety padding in the region of said through holes.
 45. The helmet of claim 42 further comprising a padding shell. 